EP3483803A1 - Wartungsoptimierungssystem durch prädiktive analyse und nutzungsintensität - Google Patents

Wartungsoptimierungssystem durch prädiktive analyse und nutzungsintensität Download PDF

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Publication number
EP3483803A1
EP3483803A1 EP18193719.4A EP18193719A EP3483803A1 EP 3483803 A1 EP3483803 A1 EP 3483803A1 EP 18193719 A EP18193719 A EP 18193719A EP 3483803 A1 EP3483803 A1 EP 3483803A1
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EP
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Prior art keywords
maintenance
equipment
data
history
computing module
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EP18193719.4A
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English (en)
French (fr)
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David Edmund JOHNSON
Stuart Gray
Krishna Uppuluri
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GE Energy Power Conversion Technology Ltd
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GE Energy Power Conversion Technology Ltd
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    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/20—Administration of product repair or maintenance
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/04—Forecasting or optimisation specially adapted for administrative or management purposes, e.g. linear programming or "cutting stock problem"
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
    • G06Q10/063—Operations research, analysis or management
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q50/00—Information and communication technology [ICT] specially adapted for implementation of business processes of specific business sectors, e.g. utilities or tourism
    • G06Q50/02—Agriculture; Fishing; Forestry; Mining
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06N—COMPUTING ARRANGEMENTS BASED ON SPECIFIC COMPUTATIONAL MODELS
    • G06N7/00—Computing arrangements based on specific mathematical models
    • G06N7/01—Probabilistic graphical models, e.g. probabilistic networks
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/80—Management or planning

Definitions

  • the present invention relates generally to performing equipment maintenance optimization.
  • the present invention relates to performing offshore industrial equipment maintenance optimization through predictive analysis and usage intensity (UI).
  • UI usage intensity
  • FIG. 1A An example of one such system is an offshore oil platform 10, illustrated in FIG. 1A .
  • the offshore oil platform 10 is an integrated system, including a drilling system 12, and marine vessels 14.
  • the drilling system 12 includes various industrial equipment components, such as a drive train 16, blow out preventers (BOPs) 18, along with various management and control networks.
  • BOPs blow out preventers
  • system maintenance can be very costly and difficult.
  • One traditional cost containment and maintenance reduction approach combines the scheduled calendar based preventive maintenance, noted above, with limited amounts of required maintenance. In this approach, the required maintenance is performed after a specific number of hours run.
  • a maintenance tracking system includes a plurality of computing modules each configured to (i) retrieve maintenance history and equipment parameters associated with a plurality of equipment from at least one network and process the maintenance history, (ii) calculate usage intensity (UI) based on the maintenance history and equipment parameters, and (iii) create modified maintenance schedules of the plurality of equipment based on the maintenance history and UI calculated.
  • a system for predicting maintenance on a plurality of equipment components includes a plurality of computing modules configured to (i) retrieve maintenance history and equipment parameters associated with the industrial equipment components from at least one equipment network, and process the maintenance history, (ii) calculate UI based on the maintenance history and equipment parameters, and (iii) create modified maintenance schedules of the plurality of equipment components based on the maintenance history and the UI.
  • the equipment parameters may comprise one or more of analog values, temperature or pressure values, control signals, reference speed and feedback signals of the plurality of equipment components.
  • the system may further include a storage in communication with the computing modules and configured to store historical data obtained and UI data calculated by the computing modules, and a software application module configured to retrieve and control performance of the modified maintenance schedules.
  • the storage and the software application module may be remotely located from the plurality of computing modules and the at least one equipment network.
  • Each computing module may include an internal memory configured to store instructions, at least one processor configured to receive the instructions from the internal memory and perform steps (i), (ii) and (iii) by the plurality of computing modules.
  • the modified maintenance schedules created may include a maintenance task timeline including a total of maintenance tasks for the equipment network, and a selected item task including maintenance for a specific piece of equipment of the plurality of equipment components.
  • the at least one processor of one computing module of the plurality of computing modules may be further configured to (i) perform a skip shift operation to determine when to extend existing maintenance tasks of the plurality of equipment components on the equipment network, wherein the skip shift operation comprises determining maintenance extension using historical maintenance data of the plurality of equipment components and skipping routine scheduled maintenance based on the historical maintenance data, and (ii) retrieving maintenance data in real-time regarding the plurality of equipment components on the at least one equipment network via a computing module of the plurality of computing modules, performing analytics using machine learning processes and shifting a maintenance schedule of the plurality of equipment components based on the analytics.
  • the modified maintenance schedules may be displayed and controlled via a user display.
  • the modified maintenance schedules may include maintenance benefit information including UI information and predictive alerts.
  • a method for predicting maintenance of a plurality of equipment components on an equipment network includes retrieving at a first computing module, maintenance history and equipment parameters associated with the plurality of equipment components from the equipment network and processing the maintenance history, calculating at a second computing module, a usage intensity factor (UIF) based on the maintenance history and values of the equipment parameter, and creating at a third computing module, modified maintenance schedules of the plurality of equipment components based on the maintenance history and the UIF.
  • UIF usage intensity factor
  • the equipment parameters may include one or more of analog values, temperature or pressure values, control signals, reference speed and feedback signals of the plurality of equipment components.
  • the method may further include storing the maintenance history and UIF, and retrieving and controlling the modified maintenance schedules via a software application module in communication with the first computing module, the second computing module and the third computing module.
  • the method may further include performing, at the third computing module, a skip shift operation to determine when to extend existing maintenance tasks of the plurality of equipment components on the equipment network.
  • the skip shift operation may include determining maintenance extension using historical maintenance data of the plurality of equipment components and skipping routine scheduled maintenance based on the historical maintenance data, and retrieving maintenance data in real-time regarding the plurality of equipment components on the at least one equipment network via the first computing module, and performing analytics using machine learning processes and shifting a maintenance schedule of the plurality of equipment components based on the analytics.
  • the method may further include displaying, at a user display, the modified maintenance schedules.
  • the method may further include displaying at the user display, maintenance benefit information including usage intensity information and predictive alerts.
  • a computer implemented equipment maintenance optimization system for one or more target assets comprising: history sensors, configured to detect and transmit maintenance history data from the TA; usage intensity sensors, configured to detect and transmit wear or usage data from the TA; a computer server-system, comprising an historian processor, a usage intensity analytics engine, and a control processor; communications interface means, operatively coupled to said sensors and server-system; first logic means for performing smart signal predicative analytics (SSPA) computations using received and stored model history data; second logic means for performing usage intensity factor analytics (UIFA) computations using received and model wear data; logical means for combining information from the firs logic means and the second logic means to determine whether maintenance events should take place at previously scheduled times, moved forward in time, or moved back to later times; and server-system logic means for calculating maintenance effectiveness, and for tracking and displaying maintenance status; whereby equipment maintenance can be optimally extended when TA is lightly used or brought forward when anomalies indicate imminent failure of the TA.
  • SSPA smart signal predicative analytics
  • UIFA usage intensity factor analytics
  • the embodiments provide a method and maintenance tracking system for performing maintenance scheduling for offshore industrial equipment (e.g., motors, transformers) within a maintenance network.
  • This maintenance is performed by monitoring associated equipment parameters and utilizing similarity-based modeling processes to detect signs of imminent equipment failure.
  • the system described herein interfaces with existing equipment networks via a communication network.
  • the communication network can be WiFi, Internet, Bluetooth, 802.11, 802.15, cellular, or other computer networks.
  • the maintenance system according to embodiments of the present invention, interface directly with existing maintenance software systems well known to those of skill in the art.
  • Systems constructed in accordance with the embodiments generate additional maintenance and inspection tasks to resolve potentially problematic issues before they produce failures. As a result, this approach reduces costly repairs and unplanned downtime by calculating usage intensity (UI) for each equipment component or subsystem.
  • UI usage intensity
  • the UI calculated assist with determining postponement of maintenance for lightly loaded equipment when downtime for maintenance is not required, resulting in extended equipment availability and overall reduced maintenance costs.
  • the system of the embodiments can be implemented within existing marine and offshore equipment systems, and drilling ships. The system can also be implemented within any industrial plant power stations or other complex equipment systems.
  • FIG. 1B illustrates a tracking system 104 for maintaining a plurality of industrial equipment components on at least one network, according to the embodiments.
  • the system 100 of the present invention will be described in reference to an offshore vessel, for illustrative purposes only.
  • the system 100 includes a plurality of computing modules 110, 120, and 130 in communication with a plurality of equipment networks 50, 55, 60, and 65.
  • the system 100 further includes a storage database 140 and software application module 150 in communication with the computing modules 110 and 120.
  • the equipment networks 50, 55, 60, and 65 can include networks associated with drilling, BOP control, vessel management, and power management, respectively.
  • the computing modules 110, 120, and 130 can be virtual machines included within a single server, or single stand-alone servers or computing devices.
  • the computing module 110 retrieves maintenance history data and equipment parameters associated with the plurality of industrial equipment systems associated via the networks 50, 55, 60, and 65.
  • the equipment parameters can include analog values such as temperature or pressure values, control signals, reference speeds, powers, torques and other feedback signals such as open/closed statuses, running stopped statuses, to name a few.
  • the computing module 110 will process the maintenance history data input from the plurality of equipment systems.
  • the information received via the networks 50, 55, 60, and 65 passes through respective network firewalls 50', 55', 60', and 65' before being input to the computing module 110. Also included in the example of FIG. 1B is an optional customer firewall 66.
  • the computing module 120 is configured to calculate a UI factor based on processed received maintenance history data and equipment parameter values output from the computing module 110.
  • the computing module 130 is configured to create modified maintenance schedules of the plurality of equipment based on the maintenance history and UI calculated via computing modules 110, 120, and 130.
  • the modified maintenance schedules can be displayed via a user interface (e.g., a computer display 70).
  • the networks 50, 55, 60 and 65 and the computing modules 110, 120, and 130 can be located offshore on a vessel and a second set of computing modules 110, 120, and 130 can be disposed onshore in a remote location for further analysis.
  • the computing modules 110, 120, and 130 offshore can communicate with the computing modules 110, 120, and 130 onshore via an existing satellite communication network 80.
  • Functions performed by the computing modules 110, 120, and 130 onshore are substantially identical to the functions performed by the computing modules 110, 120, and 130 offshore.
  • the resulting modified maintenance schedules can also be displayed on an onshore user interface 70.
  • the information can be sent to the storage module 140 and viewed and controlled via the software application module 150 at a user device.
  • the information sent to the storage module 140 and the software application module 150 can first go through a demilitarized zone (DMZ) or additional firewalls.
  • DMZ demilitarized zone
  • the storage module 140 and the software application module 150 can be located at an industrial performance and reliability center (IPRC) and information is retrieved from the computing modules 110, 120, and 130 onshore via a communication network 90 such as the Internet.
  • IPRC industrial performance and reliability center
  • Each computing module 110, 120, and 130 each can be a computing device as shown in FIG. 2 that includes a processor 220 with a specific structure.
  • the specific structure is imparted to the processor 220 by instructions stored in an internal memory 230 included therein.
  • the structure can also be imparted by instructions 240 that can be fetched by the processor 220 from a storage medium 250.
  • the storage medium 250 may be co-located with the computing module 110, 120, and 130 as shown, or it may be located elsewhere and be communicatively coupled to the respective computing module 110, 120, and 130.
  • the computing modules 110, 120, and 130 each may include one or more hardware and/or software components configured to fetch, decode, execute, store, analyze, distribute, evaluate, diagnose, and/or categorize information. Furthermore, the computing modules 110, 120, and 130 can each include an input/output (I/O) module 260 that can be configured to interface with each other and with the external networks.
  • I/O input/output
  • the processor 220 may include one or more processing devices or cores (not shown). In some embodiments, the processor 220 can be a plurality of processors, each having either one or more cores. The processor 220 can be configured to execute instructions fetched from the memory 230, or the instructions may be fetched from storage medium 250, or from a remote device connected to computing device via a communication interface 270.
  • the storage medium 250 and/or the memory 230 may include a volatile or non-volatile, magnetic, semiconductor, tape, optical, removable, non-removable, read-only, random-access, or any type of non-transitory computer-readable computer medium.
  • the storage medium 250 and/or the memory 230 may include programs and/or other information that may be used by the processor 220.
  • the storage medium 250 may be configured to log data processed, recorded, or collected during the operation of the computing modules 110, 120, or 130.
  • the storage medium 250 may store the historical data, calculated UI data, and created modified maintenance schedule data at the respective computing modules 110, 120, and 130.
  • the data may be time-stamped, location-stamped, cataloged, indexed, or organized in a variety of ways consistent with data storage practice.
  • FIG. 3 is a chart illustrating an example of a modified maintenance schedule generated within the system of FIG. 1B that can be implemented within one or more embodiments.
  • the modified maintenance schedule 310 includes a maintenance task timeline 312 and a selected item task detail 314.
  • the maintenance task timeline 312 including finished-base tasks, calendar-based tasks, UI extended tasks and predictive alerts, and tasks scheduled alerts, for example.
  • the maintenance task timeline 312 illustrates the overall maintenance tasks necessary for a network including a plurality of equipment.
  • the selected item task detail 314 illustrates maintenance for a specific piece of equipment of the plurality of equipment.
  • FIG. 4 is a flow diagram illustrating the skip and shift process 400 of the system 100 of FIG. 1B .
  • the skip shift process 400 is performed on different types of equipment, for example, top drives, and mud pumps etc.
  • Existing maintenance tracking systems typically include calendar-based maintenance that include a planned maintenance schedule to be performed monthly, every three-months, six-months, yearly, and the like.
  • the skip shift process 400 includes determining maintenance extensions to avoid unnecessary maintenance.
  • this determination can be based upon the historical data for a one (1) year period, as received from the networks 50, 55, 60, and 65 by the computing module 110 of FIG. 1B .
  • the maintenance of the industrial equipment components is shadowed and verified and based on maintenance effectiveness a "skip."
  • a skip is performed such that the routine scheduled maintenance can be skipped without damage to the equipment.
  • the maintenance effectiveness analytics performed can include equipment analysis before and after the maintenance activities.
  • step 2 of the skip shift process 400 maintenance foresight is performed to prevent unplanned downtime of the equipment by prediction of necessary maintenance.
  • Data regarding the equipment is live streamed to the computing module 110, and the maintenance of the equipment is shadowed and verified by analysis.
  • the analytics can be zonal analytics which include equipment zonal models and use of machine learning based predictions.
  • FIG. 5 is an exemplary chart 500, illustrating maintenance histories of the industrial equipment components and maintenance benefits to be displayed to a user at the user interface 70, such as a workstation.
  • the chart 500 includes maintenance benefit information including a UI report 512, and a predictive alerts report 514.
  • the UI report 512 includes the maintenance task, planned maintenance data, an advised maintenance date, and the calculated maintenance extension (i.e., the number of days extended) for each maintenance task.
  • the predictive alerts report 514 can also include the type of maintenance task, the subsystem or equipment (e.g., a gearbox), the impact of the maintenance extension (e.g., low), and/or the advised maintenance date.
  • FIG. 6 is an exemplary chart 600 illustrating recordkeeping and reporting of effectiveness of modified maintenance schedules in accordance with the embodiments.
  • the number of pieces of equipment analyzed can be calculated, along with the effective modified maintenance schedules, and the unknown effectiveness. Additionally, total extension days determined, man hours saved, ineffective maintenance extensions, and planned maintenance can be calculated.
  • the report data can be displayed and analyzed by operators at the user interface 70 for purposes of determining the effectiveness and accuracy of the system 100.
  • FIG. 7 is a flow diagram illustrating an exemplary method 700 for performing maintenance optimization through predictive analysis and UI that can be implemented within one or more embodiments of the present invention in reference to FIG. 1B .
  • the method begins at operation 710 where the computing module 110 retrieves maintenance history and equipment parameters associated with the equipment components via the networks 50, 55, 60, and 65.
  • the computing module 110 then processes the maintenance history of the industrial equipment components.
  • the process continues to operation 720 where the computing module 120 then calculates usage intensity factor (UIF) based on the maintenance history and equipment parameter values retrieved by the computing module 110.
  • the process continues to operation 730 where the computing module 130 is configured to create modified maintenance schedules of the industrial equipment components. The modifications are created as a function of the maintenance history and UI, calculated via computing modules 110, 120, and 130.
  • the modified maintenance schedules can be displayed via the user interface 70.
  • the process proceeds to operation 740 where this process is duplicated in the case of remote monitoring. From operation 740 the process continues to operation 750 where the information, including the modified maintenance schedules, maintenance history etc., is transferred to the storage module 140 and retrievable and controllable by an operator via the software application module 150.
  • Embodiments of the present invention provide the advantages of generating additional maintenance and inspection tasks to resolve issues before breakdown to reduced unplanned downtime and repairs.
  • the embodiments use principles of big data management to bring maintenance optimization to an enterprise level, providing visibility of maintenance requirements, schedules and equipment conditions to a centralized location allowing maintenance analysis and optimization to be performed.
  • the embodiments allow an operator to extend maintenance of equipment with the knowledge that any abnormalities will be detected prior to a failure occurrence.
  • target asset will be used generically to refer to a single piece of equipment (e.g., a motor or gear) or to more complex equipment having pluralities of components.
  • computer, processor, and virtual machine may be used interchangeably.
  • communication interface will be used generically to include LAN/WiFi, WAN, cloud, Internet, dedicated/private communications links, etc.
  • data and information will be used interchangeably.
  • FIG. 8 provides an upper level overview of the disclosed system 800, as applied for one network (such as anyone of networks 50, 55, 60, 65 in FIG. 1B ). This is not meant to limit the scope of the disclosed system to use with just one network, as the principles disclosed herein could be similarly, and/or simultaneously, used (under either local/distributed or remote centralized control) for a plurality of networks as those indicated in FIG. 1B .
  • the system 800 includes a target asset (TA) 804 as comprising history sensors 806 and usage sensors 808.
  • TA target asset
  • usage sensors 808 An artisan would of course recognize that such sensors could be physically located either locally (i.e., in or on the TA) or be operatively coupled to remote/central monitors, through a communications interface 820.
  • element 830 represents a computing/server system.
  • the server includes three virtual machines (VM1-element 844, VM2-element 850, VM3-element 860). Equivalent/alternative server configurations would be recognized by the artisan as within the scope of the disclosed invention.
  • VM1 is an historian processor 840. It includes a smart signal predictive analytics (SSPA) module 844. VM1 performs SSPA maintenance computations, using both incoming and stored 842 history data, in conjunction with analytics from its machine learning modules 846. VM1 combines this information to make TA performance/failure predictions, for maintaining a selected TA. For example, VM1 may compare current behavior with predicted values developed from similarity based modelling for various operating modes.
  • SSPA smart signal predictive analytics
  • VM2 is a UI analytics engine 850.
  • VM2 850 includes a UI factor analytics (UIFA) module 852.
  • UIFA UI factor analytics
  • VM2 performs UIFA computations using model behavior data (for equipment in the same class as the TA of interest), incoming sensory and stored usage data, and analytics from its own machine learning modules 854. For example, VM2 may compare (e.g., FIG. 10 ) sensed usage data, which indicates the actual amount of wear or work performed, with model baseline data developed for the specific type of TA apparatus (e.g., FIGs. 10 and 11-12 ).
  • VM3 is a control processor 860.
  • VM3 combines information from VM1 and VM2 and manages maintenance tracking and scheduling 870.
  • VM3 also uses the historical and calculated data to drive dashboards providing meaningful information on maintenance status of covered equipment, and
  • VM3 860 controls displays 880 and interactions with operators. While depicted as separate from the control processor 860; a POSITA would recognize that elements 870, 880, and 890 may be equivalently configured as physically part of the control processor, or geo-spatially removed from the control processor but operatively coupled thereto.
  • a POSITA would also recognize that some calculations, determinations, and computations ascribed to one part of the server-system could be performed in one or more other parts of the server-system without departing from the scope of the disclosed invention.
  • FIG. 9 is a flowchart for an SSPA determination embodiment 900 using a blueprint model. After a TA of interest is selected 910, a blueprint for the TA's equipment class is developed 920 and stored 926. Next, the TA's existing instrumentation 930 is used to collect historical data for multiple operating modes on a serial number basis.
  • the VM1 processor is used to implement SBM to create and store 926 a dynamic expected operating profile for the TA.
  • the VM1 processor evaluates data from each of multiple sensors, calculates ambient conditions, and determines how each TA sensor works in correlation with other sensors 954.
  • the VMI processor also creates a tight normal performance confidence range, or dynamic band 957, for the entire TA.
  • the VM1 may be used to compare current behavior with predicted values from the prior developed model. The system determines whether a failure diagnostic has been detected 960. In the example of FIG. 9 , if the answer is YES, a user alert 970 is sent via VM3.
  • FIG. 10 is flowchart 1000 for an embodiment employing UIFA determinations.
  • FIGs. 11A, 11B , and FIG.12 illustrate UIFA calculation methods for very simple 1100, simple 1102, and complex apparatuses 1200, respectively.
  • wear mechanisms are examined on a case by case basis for each target asset. For example: if the TA is a very simple apparatus (e.g., a valve), see FIG.11A ; if the TA is a simple apparatus (e.g., bearings), see FIG.11B ; if the TA is a complex apparatus, such as a gearbox, see FIG. 12 .
  • baseline usage intensity factor (UIF) components are calculated 1030 and stored 1044.
  • the UIF parameters can then be monitored and measured on a real-time basis 1050. Comparisons are then made between the baseline and run-time UIF data 1060.
  • VM2 can thus be used to process and analyze the UIFA data to picture ongoing TA wear, over the current maintenance period.
  • this UIF data processing also allows detection of anomalies and relevant trends 1070.
  • the results of the UIF analysis further enables determination of whether a maintenance extension request is appropriate (e.g., FIG.13 ). More detailed example UIF calculations are provided below.
  • the top drive power mechanism consists of multiple components, including two motors: motor A and motor B.
  • Motor A and Motor B are brought together into a dual input bull and pinion gearbox, depicted in FIG. 3 .
  • Each motor and the gearbox can be viewed independently for performing predictive maintenance and intensity usage calculations. Although calculations are performed on a case-by-case basis, several calculations performed in the examples below, are common to all systems.
  • the system 100 of FIG. 1B may detect a problem within and recommend maintenance on one or more of the components. As a result, it may be necessary to track maintenance on each of the components independently. For example, the system 100 may indicate a problem with bearings in motor A and may elect to perform maintenance on motor A only, leaving motor B unchanged.
  • the system 100 can track top drive motor and gearbox utilization, based upon predictive maintenance, in accordance with the embodiments.
  • the utilization can be determined by considering total hours run and the actual number of revolutions of each motor, or the gearbox, since last maintenance.
  • the utilization can be calculated as a function of the number of revolutions (N).
  • Rev max the maximum number of revolutions in any six (6) week period.
  • Software within the system 100, is configured to count the total number of revolutions after three (3) weeks. This count is used to project the length of time required to reach the same value of Rev max , which represents the maximum possible extension of maintenance.
  • the maximum possible extension can initially be limited to 30%.
  • the extension will be re-evaluated periodically (e.g., weekly), up to a point where maintenance is performed. This process is illustrated in a graph 1494 shown in FIG. 14 . Once maintenance has been performed, the count of the number of revolutions is desirably reset to zero (0).
  • Pow max the highest value of power transmitted in any six (6) week period can be calculated as Pow max .
  • Software within the system 100 measures a total value power transmitted after three (3) weeks. This measurement value can be used to project the length of time required to reach the same value of Pow max , which represents the maximum possible extension of maintenance. This process correlates to the maximum maintenance extension.
  • the maximum maintenance extension is initially limited to a maximum extension of 30%.
  • the possibility of extending maintenance will be re-evaluated periodically (e.g., weekly), up to a point where maintenance is performed.
  • the measurement value of the power flow is desirably reset to zero (0).
  • the system 100 can calculate stress factors by considering the acceleration of the motors A and B. If the speed of the motors is oscillating rapidly, the top drive will be subject to additional harmful stresses. Conversely, if the speed is steady, there will be less stress on the system.
  • the maximum maintenance extension is again initially limited to a maximum extension of 30%.
  • the possibly of extending maintenance will be re-evaluated periodically (e.g., weekly), up to a point where maintenance is performed. Once maintenance has been performed, the measurement value of the acceleration stress is reset to zero (0).
  • IBOP maintenance is desirably performed periodically, for example, monthly or every few months.
  • the need to perform maintenance on the IBOP is related to two areas.
  • a full cycle of the IBOP is equivalent to a transition from open to close, and back to open.
  • the IBOP operational count within any six (6) week period as being IBOP max .
  • software within the system 100 counts the total number of operations after three (3) weeks. This count is used to project the length of time required to reach the same value of IBOP max .
  • a goose-neck is another component, subjected to wear, for which predictive maintenance would be particularly advantageous.
  • a goose-neck is a thick metal elbow that interacts with other components to support the weight of high pressure hoses.
  • a major cause for wear on the goose-neck is mud flowing through it, which erodes the inner surfaces of the pipe.
  • Goose-necks are typically replaced rather than maintained. This exercise can be especially costly when unworn, and still functional goose-necks, are replaced.
  • Table 1595 provides values related to gallons per minute (strokes per minute multiplied by volume per stroke) of mud flow.
  • FIG. 13 an overview diagram illustrating maintenance rationalization and rescheduling 1300 is provided.
  • Traditional schedule-based maintenance typically covers maintenance for equipment designed to run at high loads for extended periods of time. Often equipment is operated at far lighter loads than the design nominal; hence the equipment is subject to less wear and needs less frequent maintenance. If necessary recommended maintenance activities, which fall under a scheduled maintenance event, can be reorganized in line with findings. Maintenance events can be extended (or delayed/postponed) in line with usage provided from historical analyses.
  • VM3 receives SSPA signals (from VM1) and UIFA signals (from VM2). VM3 then determines if SSPA detected TA operational degradation 1320. If an alert flag has been received from SSPA 1322, then VM3 calls for escalating the TA's maintenance cycle 1324 and performing the necessary maintenance event at an earlier time than previously scheduled.
  • VM3 also dynamically prioritizes the urgency of the received failure warning 1326. If a more urgent problem is identified after review by subject matter experts, an automatic maintenance request would be submitted to the maintenance system controller, thereby triggering appropriate corrective responses.
  • the system then advances 1328 the TA's maintenance schedule accordingly 1670. Updates are then transmitted to the TA status and tracking modules. (E.g., see FIG. 16A .) This information is also used in determining management effectiveness 1390.
  • VM3 determines if the UIFA signals (which indicate ongoing equipment usage) include recommended delays or extensions of one or more TA maintenance events 1340. If no delay/extension flag is detected, maintenance continues as previously scheduled 1350.
  • VM3 can call for an extension (or stretching-out) of the TA's maintenance schedule 1344.
  • extension period the system continues to use SSPA to monitor the TA as a safety net. Thereby, maintenance events can be brought forward if TA shows signs of degradation during the extension period 1360.
  • Receipt of a flag indicating that a maintenance event may be delayed actuates computations to determine if implementation of a "skip & shift" process 1348 is appropriate; and if so, for how long. (e.g., see FIGs. 3-5 , 16A, and 16B ).
  • TA status and tracking information is updated 1330 and data is generated for determining management effectiveness 1390.
  • FIG. 16B is an overview flowchart illustrating an example of skip & Shift method 1600.
  • Skip and shift refers to the way scheduled preventative maintenance can be shifted out (extended), based on equipment UI.
  • VM3 860 receives a scheduling signal 1604. As maintenance is extended through time, some tasks can be skipped 1620. Combining UIFA and SSPA allows a unique mechanism to extend or postpone maintenance periods, resulting in reduced maintenance down time and reduced material costs.
  • VM3 860 updates status and tracking data.
  • Zonal UI Analytics (1610, 1920) indicate how far maintenance can be extended. A full set of UIFA and SSPA factors is considered for each asset.
  • chart 1700 of FIG. 17 depicts several illustrative skip & shift parameters based upon zonal analytics in column 1710 for selected target assets 1720.
  • Column 1730 includes parameters based on predictive maintenance modeling principles.
  • FIG. 16A is an exemplary timeline diagram comparing Calendar scheduled maintenance vs Extended maintenance vs Advanced maintenance.
  • the upper timeline 1650 illustrates calendar scheduled maintenance.
  • the middle timeline 1660 illustrates postponed "skip & shift" event movement along the timeline, whereby some maintenance events are delayed until a later time.
  • the lower timeline 1670 illustrates advanced maintenance, whereby one of more events are performed at an earlier time than previously scheduled.
  • FIG.s 18 & 19A illustrates aspects of Maintenance Effectiveness Analytics 1800 and 1910 as employed in the Embodiments.
  • the management effectiveness analytics include before-and-after analysis 1912 to help make decisions on the expected target asset MER (Management Effectiveness Rating) and history data analysis 1914.
  • Maintenance can be broadly categorized as effective maintenance, ineffective maintenance, and detrimental maintenance.
  • zonal analytics 1920 including UI based maintenance extension estimates 1922 and UIA 1924.
  • a digital twin analytics module 1930 includes a digital twin degradation analysis 1932 and a simulation-based modeling analysis 1934.
  • Effective maintenance occurs where equipment begins to show signs of graceful degradation before maintenance carried out. Equipment returns to nominal status after maintenance. Ineffective maintenance occurs where there is no noticeable change in key operating parameters before or after the maintenance. No SPA alerts are generated before maintenance is carried out and maintenance is carried out unnecessarily. Detrimental maintenance is defined as having degradation in key operating parameters after maintenance.
  • the maintenance tracking system notifies the server-system. For example, if the maintenance task was a corrective action raised on the basis of a SSPA predictive insight 1812, calendar maintenance schedules 1814, and UIPA 1816, each task is analyzed to ascertain how effective the maintenance was 1820. the asset model should return to its nominal modelled state. For example, predictive maintenance, effectiveness may be determined by looking at key parameters such as temperature, since changes in these parameters show how effective the maintenance has been 1836.
  • Each maintenance task that has been carried out is assigned 1832 an overall MER.
  • the MER data is combined with zonal analytics (SSPA, UIPA) to enhance data-driven maintenance 1840.
  • the server-system also: continuously monitors MER data 1834, stores history of MER changes 1836, and updates the TA's maintenance dashboard.
  • MER data is feedback into the maintenance scheduling system to allow continuous system learning and improved modelling 1850.
  • the TA maintenance dashboard is then updated 1860.
  • the disclosed invention tracks maintenance status for each TA. For example, see: FIG. 8 (890), FIG. 13 (1330), and FIG. 18 (1860). Comprehensive summaries of maintenance operations are generated providing details of hours spent, material costs and comparisons with original calendar (e.g., see FIGs. 6 , 16B ). Equipment usage over time is tracked along with associated effect on scheduling (e.g., see FIG. 3 ).
  • Audit histories are generated which show any schedule changes and that number of days the maintenance has been extended (e.g., see FIG. 5 ). Also provided are intuitive user interfaces and dashboards (e.g., see elements 70, 110, 250, 880, 1860), which allow review of maintenance histories and overview of effectiveness.
  • FIG. 19B is an overview 1950 illustrating how combinations of different analytic technologies and methodologies can be combined to drive data-driven predictive maintenance schedules.
  • a few of the analytic technologies are management effectiveness analytics, historical data analysis, zonal analytics, UI analysis, digital twin analytics, and similarly based modelling analysis.
  • This system has several advantages over existing standalone control and condition based monitoring system.
  • Traditional calendar systems, or CBM provide local indication of potential equipment failure.
  • the embodiments use principles of big data management to bring maintenance optimization to an enterprise level. This process also moves visibility of maintenance requirements, schedules and equipment conditions to a centralized location, which allows fleet wide analysis and optimization to be performed.
  • the combination of UI and predictive analytics provides the operator confidence when scheduling maintenance that any abnormalities will be detected prior to a failure.
  • the unique concept of timestamping pre and post maintenance, using the residual values from the predictive model and actual readings, allows visualization of the effectiveness of the maintenance.

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